System Specifications
Engine Mechanical SpecificationsCylinder Head Deck Height-Measuring from the Centerline of Crankshaft to the Deck Face; 234.57-234.82 mm (9.235-9.245 inch)
Cylinder Head Deck Surface Flatness-Measured Within a 152.4 mm (6.0 inch) Area; 0.11 mm (0.004 inch)
Cylinder Head Deck Surface Flatness-Measuring the Overall Length of the Block Deck; 0.22 mm (0.008 inch)
Cylinder Bore Diameter 96.0-96.018 mm (3.779-3.787 inch)
Cylinder Bore Taper-Thrust side 0.018 mm (0.0007 inch)
Connecting Rod Journal Diameter- Production 53.318-53.338 mm (2.0991-2.0999 inch)
Connecting Rod Journal Diameter- Service 53.308 mm (2.0987 inch)
Connecting Rod Journal Out-of-Round - Production 0.005 mm (0.0002 inch)
Connecting Rod Journal Out-of-Round - Service 0.01 mm (0.0004 inch)
Connecting Rod Journal Taper- Maximum for 1/2 of Journal Length - Production; 0.005 mm (0.0002 inch)
Connecting Rod Journal Taper- Maximum for 1/2 of Journal Length - Service 0.02 mm (0.00078 inch)
Crankshaft End Play 0.04-0.2 mm (0.0015-0.0078 inch)
Crankshaft Main Bearing Clearance - Production 0.02-0.052 mm (0.0008-0.0021 inch)
Crankshaft Main Bearing Clearance - Service 0.02-0.065 mm (0.0008-0.0025 inch)
Crankshaft Main Journal Diameter- Production 64.993-65.007 mm (2.558-2.559 inch)
Crankshaft Main Journal Diameter- Service 64.993 mm (2.558 inch)
Crankshaft Main Journal Out-of-Round - Production 0.003 mm (0.000118 inch)
Crankshaft Main Journal Out-of-Round - Service 0.008 mm (0.0003 inch)
Crankshaft Main Journal Taper- Production 0.01 mm (0.0004 inch)
Crankshaft Main Journal Taper- Service 0.02 mm (0.00078 inch)
Crankshaft Rear Flange Runout 0.05 mm (0.002 inch)
Crankshaft Reluctor Ring Runout - Measured 1.0 mm (0.04 in Below Tooth Diameter; 0.7 mm (0.028 inch)
Crankshaft Thrust Surface - Production 26.14-26.22 mm (1.029-1.0315 inch)
Crankshaft Thrust Surface - Service 26.22 mm (1.0315 inch)
Crankshaft Thrust Surface Runout 0.025 mm (0.001 inch)
Piston - Piston Diameter - Measured Over Skirt Coating; 96.002-96.036 mm (3.779-3.78 inch)
Piston - Piston to Bore Clearance - Production 0.036-0.016 mm-0.0014-0.0006
Piston - Piston to Bore Clearance - Service Limit with Skirt Coating Worn Off; 0.071 mm (0.0028 inch)
Pin - Piston Pin Fit in Connecting Rod Bore; 0.02-0.043 mm Interference (0.00078-0.00169 in - interference
Pin - Piston Pin Clearance to Piston Pin Bore - Production; 0.007-0.02 mm (0.00027-0.00078 inch)
Pin - Piston Pin Clearance to Piston Pin Bore - Service; 0.007-0.021 mm (0.00027 - 0.00082 inch)
Pin - Piston Pin Diameter 23.997-24.0 mm (0.9447-0.9448 inch)
Fastener Tightening Specifications
Crankshaft Bearing Cap Bolts - inner Bolts - First Pass; 20 Nm (15 ft. lbs.)
Crankshaft Bearing Cap Bolts - inner Bolts - Final Pass; 80 degrees
Crankshaft Bearing Cap Bolts - Outer Bolts - First Pass; 20 Nm (15 ft. lbs.)
Crankshaft Bearing Cap Bolts - Outer Bolts - Final Pass; 51 degrees
Crankshaft Bearing Cap Side Bolts 25 Nm (18 ft. lbs.)
Crankshaft Balancer Bolt
Installation Pass to Ensure the Balancer is Completely installed; 330 Nm (240 ft. lbs.)
First Pass - install a NEW Bolt After the installation Pass and Tighten as Described in the First and Final Passes; 50 Nm (37 ft. lbs.)
Final Pass 140 degrees